Method for making a dual chamber bottle

ABSTRACT

A multiple-chamber container that is extrusion blow molded with a single neck finish and a method to trim the single neck finish is provided. The physical appearance of the multiple-chamber container before the trimming process differs from the multiple-chamber container after the trimming process. The multiple-chamber container includes multiple openings that are configured to engage with a single cap after the trimming process to create a seal. The multiple-chamber container may contain different materials, such as liquids, gel-like substances, granular materials, food, etc. that are not permitted to flow from one chamber to the other chamber when the cap is engaged with the chamber openings.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application is a continuation-in-part of U.S. application Ser. No.14/527,051, filed Oct. 29, 2014, which is incorporated herein byreference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates to a dual chamber extrusion blow moldedcontainer with a single neck finish in which the chambers hold a liquid,gel-like substance, granular materials, food etc. and may be sealed witha single cap. In particular, the present invention relates specificallyto a container or a method which provides separation between thecontainer chambers extending from the bottom of the container to the topof the sealing surface of the single neck finish.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to a multiple-chamber container.The multiple-chamber container includes a first tapered neck portion, afirst chamber, a second tapered neck portion, a second chamber, a hollowcylindrical collar and a transition portion. The first chamber includesa first bottom wall and a first side wall formed with the first bottomwall and terminating at the first tapered neck portion which defines afirst opening into the first chamber. The second chamber includes asecond bottom wall substantially coplanar with the first bottom wall anda second side wall formed with the second bottom wall and terminating atthe second tapered neck portion which defines a second opening into thesecond chamber. Each neck portion includes a semi-circular shapedexternal surface having an external thread. The hollow cylindricalcollar has a circular cross-section defining a substantially circularopening. The transition portion provides a content-tight junctionbetween the first and second neck portions and the hollow cylindricalcollar such that any content passing between either chamber and thecircular opening must pass through the hollow cylindrical collar.

Another embodiment of the invention relates to a multiple-chambercontainer. The multiple-chamber container includes a first chamber, asecond chamber, a hollow cylindrical collar and a transition portion.The first chamber includes a first bottom wall and a first side wallformed with the first bottom wall and terminating at a first taperedneck portion which defines a first opening into the first chamber,wherein the first tapered neck portion includes a first neck wall facingthe second tapered neck portion. The second chamber includes a secondbottom wall substantially coplanar with the first bottom wall and secondside wall formed with the second bottom wall and terminating at a secondtapered neck portion which defines a second opening into the secondchamber. Each neck portion includes a semi-circular shaped surfacehaving an external thread. The second tapered neck portion includes asecond neck wall facing the first tapered neck portion. Each neckportion includes at least 2 ribs on the neck walls. The hollowcylindrical collar has a circular cross-section defining a substantiallycircular opening. The transition portion provides a content-tightjunction between the first and second neck portions and the hollowcylindrical collar such that any content passing between either chamberand the circular opening must pass through the hollow cylindricalcollar. The transition portion includes a plurality of cross-sectionalshapes with at least one of the shapes at one of the cross-sectionsincludes 2 opposed, hollow D-shaped surfaces. The walls, hollowcylindrical collar and transition portion being formed from 1 or morelayers of thermoplastic material with each adjacent layer beingdifferent from the other.

Another embodiment of the invention relates to a method of forming amultiple-chamber container. The method of forming a multiple-chambercontainer includes extruding a molten plastic extrusion, closing a moldaround the extrusion, forcing a gas into the extrusion and removing thehollow cylindrical collar from the neck portion. The molten plasticextrusion is formed from 1 or more different types of thermoplasticmaterials to produce 1 or more layers of adjacent thermoplasticmaterials wherein adjacent layers are different from each other. Theclosed mold includes an interior mold wall defining an interior shape.The gas into the extrusion is to expand the extrusion into contact withthe interior mold wall to form a container having an outside shape. Theoutside shape of the container differing from the interior shape of themold by an amount defined by the effects of thermal deformationoccurring during the forming process. The mold includes an interiorshape causing the container to include a first chamber, a secondchamber, a hollow cylindrical collar and a transition portion. The firstchamber includes a first bottom wall and a first side wall formed withthe first bottom wall and terminating at a first tapered neck portionwhich defines a first opening into the first chamber. The second chamberincludes a second bottom wall substantially coplanar with the firstbottom wall and a second side wall formed with the second bottom walland terminating at a second tapered neck portion which defines a secondopening into the second chamber. Each neck portion includes asemi-circular shaped surface having an external thread. The hollowcylindrical collar has a circular cross-section defining a substantiallycircular opening. The transition portion provides a content-tightjunction between the first and second neck portions and the hollowcylindrical collar such that any content passing between either chamberand the circular opening must pass through the hollow cylindricalcollar. Removing the hollow cylindrical collar from the neck portion atthe transition portion to produce a container having a coplanar topsurface circumscribing two non-circular openings.

Alternative exemplary embodiments relate to other features andcombinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingfigures, wherein like reference numerals refer to like elements inwhich:

FIG. 1 is a perspective view of a multiple-chamber container before atrimming process according to an exemplary embodiment;

FIG. 2 is a front view of the multiple-chamber container of FIG. 1before the trimming process according to the exemplary embodiment;

FIG. 3 is a cross-sectional view of the multiple-chamber container ofFIG. 1 taken along line 3-3 in FIG. 2 according to an exemplaryembodiment;

FIG. 4 is a detailed view of the area of the multiple-chamber containerlabeled as 4 in FIG. 2 according to an exemplary embodiment;

FIG. 5 is a top plan view of the multiple-chamber container of FIG. 1according to an exemplary embodiment;

FIG. 6A is a cross-sectional view of the multiple-chamber container ofFIG. 1 taken along line 6A-6A in FIG. 4 according to an exemplaryembodiment;

FIG. 6B is a cross-sectional view of the multiple-chamber container ofFIG. 1 taken along line 6B-6B in FIG. 4 according to an exemplaryembodiment;

FIG. 7 is a perspective view of the multiple-chamber container of FIG. 1after the trimming process according to an exemplary embodiment;

FIGS. 8A-8C illustrates the trimming process of the multiple-chambercontainer according to an exemplary embodiment;

FIGS. 9A-9D illustrates the trimming process of the multiple-chambercontainer according to another exemplary embodiment; and

FIG. 10 is a flow-diagram showing a method for forming themultiple-chamber container according to an exemplary embodiment.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplaryembodiments in detail, it should be understood that the presentapplication is not limited to the details or methodology set forth inthe description or illustrated in the figures. It should also beunderstood that the terminology is for the purpose of description onlyand should be regarded as limiting.

Referring generally to the figures, in one embodiment a multiple-chambercontainer that is extrusion blow molded with a single neck finish and amethod to trim the single neck finish is provided. The physicalappearance of the multiple-chamber container before the trimming processdiffers from the multiple-chamber container after the trimming process.The multiple-chamber container includes multiple openings that areconfigured to engage with a single cap after the trimming process tocreate a seal. The multiple-chamber container may contain liquids,granular materials, gel-like substances, food, etc. that are notpermitted to flow from one chamber to the other chamber when the cap isengaged with the chamber openings. The multiple-chamber container maycontain different substances in each chamber. For example, one chambermay contain a liquid substance and the second chamber may include a dryproduct, such as a granular material.

FIG. 1 illustrates an embodiment of a molded multiple-chamber container10 before a trimming process (shown in FIGS. 8A-8C and FIGS. 9A-9D). Thetrimming processes will be discussed in detail below. Themultiple-chamber container 10 includes a first tapered neck portion 12,a first chamber 14, a second tapered neck portion 16, a second chamber18, a hollow cylindrical collar 20, a transition portion 22 and a bridge36 (shown in FIG. 2). The multiple-chamber container 10 is molded, allor in part, of plastic (e.g., blow molded from a thermoplastic such aspolyethylene).

Referring to FIG. 2, the first chamber 14 includes a first bottom wall24 that is integrally formed with a first side wall 26. The secondchamber 18 includes a second bottom wall 28 that is integrally formedwith a second side wall 30. The first side wall 26 extends upwards, awayfrom the first bottom wall 24 and terminates at the first tapered neckportion 12. The second side wall 30 extends upwards, away from thesecond bottom wall 28 and terminates at the second tapered neck portion16. The second bottom wall 28 is substantially coplanar with the firstbottom wall 24. In the exemplary embodiment, the first chamber 14 andthe second chamber 18 are mirror images of each other. In otherembodiments, the first chamber 14 and the second chamber 18 may havedifferent dimensions.

Referring to FIG. 2, the first tapered neck portion 12 extends upwardsfrom the first side wall 26 towards a first threaded portion 32. Thesecond tapered neck portion 16 extends upwards from the second side wall30 towards a second threaded portion 34. The first threaded portion 32and the second threaded portion 34 are adjacent to the transitionportion 22. The transition portion 22 is generally annular in shapeextending from the first threaded portion 32 and the second threadedportion 34 towards the hollow cylindrical collar 20. In the exemplaryembodiment, the first tapered neck portion 12 between the first chamber14 and the first threaded portion 32 is a mirror image of the secondtapered neck portion 16 between the second chamber 18 and the secondthreaded portion 34. In other embodiments, the first tapered neckportion 12 between the first chamber 14 and the first threaded portion32 may have different dimensions than the second tapered neck portion 16between the second chamber 18 and the second threaded portion 34.

Referring to FIG. 2, the first tapered neck portion 12 includes thefirst threaded portion 32, a first shoulder wall 60, a first neck frontwall 62, a first neck back wall (not visible in figure), a first neckside wall 64, a first neck front channel wall 65 and a first neck backchannel wall (not visible in figure). The first neck front wall 62, thefirst neck back wall, the first neck side wall 64, first neck frontchannel wall 65 and the first neck back channel wall are integrallyformed with each other and are adjacent to the first side wall 26 of thefirst chamber 14. The first neck front wall 62, the first neck side wall64, the first neck back wall, the first neck front channel wall 65 andthe first neck back channel wall extend from the first chamber 14towards the first shoulder wall 60. The first neck side wall 64 tapersthe first tapered neck portion 12, extending from the first side wall 26at an angle upward towards the bridge 36. Therefore, the length of thefirst neck front wall 62 and the first neck back wall is greater nearthe first chamber 14 than the length near the first shoulder wall 60.The distance of the first neck side wall 64 between the first neck frontwall 62 and the first neck back wall is substantially the same from thefirst chamber 14 to the first shoulder wall 60. In the exemplaryembodiment, the first neck front wall 62 is substantially parallel withthe first neck back wall extending between the first chamber 14 and thefirst shoulder wall 60. In other embodiments, the first neck front wall62 and the first neck back wall may be angled, therefore, the distancebetween the first neck front wall 62 and the first neck back wall mayvary between the first chamber 14 and the first shoulder wall 60. Forexample, the distance between the first neck front wall 62 and the firstneck back wall may decrease as the first neck side wall 64 extends fromthe first chamber 14 to the first shoulder wall 60, therefore the lengthof the first neck side wall 64 decreases as the first neck side wall 64extends from the first chamber 14 to the first shoulder wall 60.

Referring to FIG. 2, the second tapered neck portion 16 includes thesecond threaded portion 34, a second shoulder wall 66, a second neckfront wall 68, a second neck back wall (not shown), a second neck sidewall 70, a second neck front channel wall 71 and a second neck backchannel wall (not shown). The second neck front wall 68, the second neckback wall, the second neck side wall 70, the second neck front channelwall 71 and the second neck back channel wall are integrally formed witheach other and are adjacent to the second side wall 30 of the secondchamber 18. The second neck front wall 68, the second neck side wall 70,the second neck back wall, the second neck front channel wall 71 and thesecond neck back channel wall extend from the second chamber 18 towardsthe second shoulder wall 66. The second neck side wall 70 tapers thesecond tapered neck portion 16, extending from the second side wall 30at an angle upwards toward the bridge 36. Therefore, the length of thesecond neck front wall 68 and the second neck back wall is greater nearthe second chamber 18 than the length near the second shoulder wall 66.The distance of the second neck side wall 70 between the second neckfront wall 68 and the second neck back wall is substantially the samefrom the second chamber 18 to the second shoulder wall 66. In theexemplary embodiment, the second neck front wall 68 is substantiallyparallel with the second neck back wall extending between the secondchamber 14 and the second shoulder wall 66. In other embodiments, thesecond neck front wall 68 and the second neck back wall may be angled,therefore, the distance between the second neck front wall 68 and thesecond neck back wall may vary between the second chamber 18 and thesecond shoulder wall 66. For example, the distance between the secondneck front wall 68 and the second neck back wall may decrease as thesecond neck side wall 70 extends from the second chamber 18 to thesecond shoulder wall 66, therefore the length of the second neck sidewall 70 decreases as the second neck side wall 70 extends from thesecond chamber 18 to the second shoulder wall 66.

Referring to FIG. 2, the bridge 36 separates the first chamber 14 andthe second chamber 18. The bridge 36 separates the first tapered neckportion 12 and the second tapered neck portion 16. The bridge 36 is aportion of the first side wall 26 and a portion of the second side wall30 near the center of the multiple-chamber container 10 that is commonto both the first side wall 26 and the second side wall 30. The bridge36 extends from the transition portion 22 down towards the first bottomwall 24 and the second bottom wall 28. The bridge 36 includes a bottomsurface 38 that extends between the first chamber 14 and the secondchamber 18. The bottom surface 38 is parallel with the first bottom wall24 and the second bottom wall 28. In the exemplary embodiment, thebottom surface 38 is non-planar with the first bottom wall 24 and thesecond bottom wall 28. The multiple-chamber container 10 has a distanceH1 between the first bottom wall 24 and the second bottom wall 28 andthe bottom surface 38 of the bridge 36. In other embodiments, the bottomsurface 38 may be coplanar with the first bottom wall 24 and the secondbottom wall 28.

Referring to FIG. 3, the first side wall 26 includes a first front wall40, a first back wall 42, a first front channel wall 44, a first backchannel wall 46, a left side wall 48 and has a width W1 extendingbetween the first front wall 40 and the first back wall 42. The firstfront wall 40, the first back wall 42, the first front channel wall 44,the first back channel wall 46 and the left side wall 48 of the firstchamber 14 are adjacent to the first neck front wall 62, the first neckback wall, the first neck front channel wall 63, the first neck backchannel wall and the first neck side wall 64 of the first tapered neckportion 12, respectively. The first front wall 40 extends from the leftside wall 48 towards the first front channel wall 44 at an angleapproximately greater than 90°. The first back wall 42 extends from theleft side wall 48 towards the first back channel wall 46 at an angleapproximately greater than 90°. The first front channel wall 44 extendsfrom the first front wall 40 towards the bridge 36 at angleapproximately greater than 90°. The first back channel wall 46 extendsfrom the first back wall 42 towards the bridge 36 at an angleapproximately greater than 90°. The left side wall 48, the first frontwall 40, the first back wall 42, the first front channel wall 44 and thefirst back channel wall 46 form a hollow rectangular cross-section thatextends between the first bottom wall 24 and the first tapered neckportion 12. In other embodiments, the walls of the first chamber 14 mayhave cross-sections that are more square or oval in shape. In otherembodiments, the cross-section of the first chamber 14 may vary inshapes. For example, the first chamber 14 may have a rectangularcross-section near the first bottom wall 24 and transitions into more ofa square cross-section near the first tapered neck portion 12.

Referring to FIG. 3, the first front wall 40 and the first back wall 42have a distance D1. The distance D1 adjacent to the left side wall 48 issubstantially similar to the width W1. The distance D1 increases as thefirst front wall 40 and the first back wall 42 extend away from the leftside wall 48 towards the first front channel wall 44 and the first backchannel wall 46, respectively. For example, the width W1 of the leftside wall 48 may be approximately 3.5 cm and the distance D1 between thefirst front wall 40 and the first back wall 42 may be 3.5 cm or slightlygreater, e.g., 3.55 cm, and the distance D1 between the first front wall40 and the first back wall 42 towards the first front channel wall 44and the first back channel wall 46 may be approximately 3.8 cm. In otherembodiments, the distance D1 between the first front wall 40 and thefirst back wall 42 may be substantially similar from the left side wall48 extending the entire way to the first front channel wall 44 and thefirst back channel wall 46. In other embodiments, the distance D1between the first front wall 40 and the first back wall 42 may besubstantially similar towards the left side wall 48 and the first frontchannel wall 44 and first back channel wall 46, but with varyingdistances in between the left side wall 48 and the first front channelwall 44 and the first back channel wall 46.

Referring to FIG. 3, the second side wall 30 includes a second frontwall 50, a second back wall 52, a second front channel wall 54, a secondback channel wall 56, a right side wall 58 and has a width W2 extendingbetween the second front wall 50 and the second back wall 52. The secondfront wall 50, the second back wall 52, the second front channel wall54, the second back channel wall 56 and the right side wall 58 of thesecond chamber 18 are adjacent to the second neck front wall 68, thesecond neck back wall, the second neck front channel wall 71, the secondneck back channel wall and the second neck side wall 70 of the secondtapered neck portion 16, respectively. The second front wall 50 extendsfrom the right side wall 58 towards the second front channel wall 54 atan angle approximately greater than 90°. The second back wall 52 extendsfrom the right side wall 58 towards the second back channel wall 56 atan angle approximately greater than 90°. The second front channel wall54 extends from the second front wall 50 towards the bridge 36 at anangle approximately greater than 90°. The second back channel wall 56extends from the second back wall 52 towards the bridge 36 at an angleapproximately greater than 90°. The right side wall 58, the second frontwall 50, the second back wall 52, the second front channel wall 54, thesecond back channel wall 56 form a hollow rectangular cross-section thatextends between the second bottom wall 28 to the second tapered neckportion 16. In other embodiments, the walls of the second chamber 18 mayhave cross-sections that are more square or oval in shape. In otherembodiments, the cross-section of the second chamber 18 may vary inshapes. For example, the second chamber 18 may have a rectangularcross-section near the second bottom wall 28 and transitions into moreof a square cross-section near the second tapered neck portion 16.

Referring to FIG. 3, the second front wall 50 and the second back wall52 have a distance D2. The distance D2 adjacent to the right side wall58 is substantially similar to the width W2. The distance D2 increasesas the second front wall 50 and the second back wall 52 extend away fromthe right side wall 58 towards the second front channel wall 54 and thesecond back channel wall 56, respectively. For example, the width W2 ofthe right side wall 58 may be approximately 3.5 cm and the distance D2between the second front wall 50 and the second back wall 52 may be 3.5cm or slightly greater, e.g., 3.55 cm, and the distance D2 between thesecond front wall 50 and the second back wall 52 towards the secondfront channel wall 54 and the second back channel wall 56 may beapproximately 3.8 cm. In other embodiments, the distance D2 between thesecond front wall 50 and the second back wall 52 may be substantiallysimilar from the right side wall 58 extending the entire way to thesecond front channel wall 54 and the second back channel wall 56. Inother embodiments, the distance D2 between the second front wall 50 andthe second back wall 52 may be substantially similar towards the rightside wall 58 and the second front channel wall 54 and second backchannel wall 56, but with varying distances in between the right sidewall 58 and the second front channel wall 54 and the second back channelwall 56.

Referring to FIG. 3, the first front channel wall 44, the bridge 36 andthe second front channel wall 54 form a front channel 72. The frontchannel 72 forms a gap that separates the first chamber 14 and thesecond chamber 18 between the first front wall 40 and the second frontwall 50. The front channel 72 extends from the transition portion 22 tothe first bottom wall 24 and the second bottom wall 28 and alsoseparates the first tapered neck portion 12 and the second tapered neckportion 16 between the first neck front wall 62 and the second neckfront wall 68 (shown in FIG. 2). The first back channel wall 46, thebridge 36 and the second back channel wall 56 form a rear channel 74.The rear channel 74 forms a gap that separates the first chamber 14 andthe second chamber between the first back wall 42 and the second backwall 52. The rear channel 74 extends from the transition portion 22 tothe first bottom wall 24 and the second bottom wall 28 and alsoseparates the first tapered neck portion 12 and the second tapered neckportion 16 between the first neck back wall and the second neck backwall (not shown). The front channel 72 is located approximately 180°from the rear channel 74. In the exemplary embodiment, the front channel72 and the rear channel 74 are mirror images of each other. In otherembodiments, the front channel 72 and the rear channel 74 may havedifferent dimensions. For example, the front channel 72 may have agreater distance between the first front wall 40 and the second frontwall 50 than the distance between the first back wall 42 and the secondback wall 52.

Referring to FIG. 4, the first shoulder wall 60 extends horizontallyinwards from the first neck front wall 62, the first neck side wall 64,the first neck back wall, the first neck front channel wall 65 and thefirst neck back channel wall towards the first threaded portion 32. Thefirst shoulder wall 60 is generally perpendicular to the first neck sidewall 64, first neck front wall 62, the first neck back wall, the firstneck front channel wall 65 and the first neck back channel wall. Thefirst shoulder wall 60 is generally parallel with the first bottom wall24 (shown in FIG. 2). The first shoulder wall 60 is semi-circular inshape that extends approximately 180° from the front channel 72 towardsthe first neck side wall 64 to the rear channel 74 (not visible infigure). The second shoulder wall 66 extends horizontally inwards fromthe second neck front wall 68, the second neck side wall 70, the secondneck back wall, the second neck front channel wall 71 and the secondneck back channel wall towards the second threaded portion 34. Thesecond shoulder wall 66 is generally perpendicular to the second neckside wall 70, second neck front wall 68, the second neck back wall, thesecond neck front channel wall 71 and the second neck back channel wall.The second shoulder wall 66 is generally parallel with the second bottomwall 28 (shown in FIG. 2). The second shoulder wall 66 is semi-circularin shape that extends approximately 180° from the front channel 72towards the second neck side wall 70 to the rear channel 74 (not shown).In other embodiments the first shoulder wall 60 and the second shoulderwall 66 may extend at an angle from the first neck side wall 64 and thesecond neck side wall 70, respectively. In other embodiments, only oneof the shoulder walls may extend at an angle towards the front channel72 and the rear channel 74 and the other shoulder wall may extendhorizontally inwards towards the front channel 72 and the rear channel74.

Referring to FIG. 4, the first threaded portion 32 includes a firstthreaded wall 76 with an external surface, a first external thread 78, afirst top surface 80, a first front rib wall 79 and a first rear ribwall (not visible in figure). The first threaded wall 76 extends betweenthe first shoulder wall 60 and the first top surface 80. The firstthreaded wall 76 is semi-circular in shape and extends approximately180° from the first front rib wall 79, away from the second threadedportion 34, towards the first rear rib wall. The first external thread78 extends from the external surface of the curved portion of the firstthreaded wall 76. The first front rib wall 79 extends radially outwardsfrom the bridge 36 towards the first threaded wall 76. On the oppositeside of the bridge 36 from the first front rib wall 79, the first rearrib wall extends radially outwards from the bridge 36 towards the firstthreaded wall 76. The second threaded portion 34 includes a secondthreaded wall 82 with an external surface, a second external thread 84,a second top surface 86, a second front rib wall 85 and a second rearrib wall (not visible in figure). The second threaded wall 82 extendsbetween the second shoulder wall 66 and the second top surface 86. Thesecond threaded wall 82 is semi-circular in shape and extendsapproximately 180° from the second front rib wall 85, away from thefirst threaded portion 32, towards the second rear rib wall. The secondexternal thread 84 extends from the external surface of the curvedportion of the second threaded wall 82. The second front rib wall 85extends radially outwards from the bridge 36 towards the second threadedwall 82. On the opposite side of the bridge 36 from the second front ribwall 85, the second rear rib wall extends radially outwards from thebridge 36 towards the second threaded wall 82.

Referring to FIG. 4, the semi-circular shaped surfaces of the firstthreaded wall 76 and the second threaded wall 82 are separated by thetwo gaps formed by the front channel 72 and the rear channel 74 (notshown in figure) and lay within a circular plane. In the exemplaryembodiment, the distance between the first threaded wall 76 and thesecond threaded wall 82 at points 180° from each other is less than thedistance between the first neck side wall 64 and the second neck sidewall 70 at points 180° away from each other. For example, the distancebetween the first threaded wall 76 and the second threaded wall 82 atpoints approximately 180° from each other may be between 30-40 mm, morespecifically approximately 34 mm and the distance between the first neckside wall 64 and the second neck side wall 70 at points 180° from eachother may be between 40-55 mm, more specifically approximately 48 mm. Inother embodiments, the distance between the first threaded wall 76 andthe second threaded wall 82 180° away from each other may besubstantially the same as or greater than the distance between the firstneck side wall 64 and the second neck side wall 70 at points that are180° from each other.

Referring to FIG. 4, the first front rib wall 79, the first rear ribwall, the second front rib wall 85 and the second rear rib wall includea plurality of ribs 89 having a rounded surface. The first front ribwall 79 and the first rear rib wall each include two ribs 89 that extendradially outward from the bridge 36 towards the first threaded wall 76.The second front rib wall 85 and the second rear rib wall each includetwo ribs 89 that extend radially outward from the bridge 36 towards thesecond threaded wall 82. The ribs 89 have a proximal end (not shown infigure) and a distal end 87. The proximal end is the portion of the ribs89 that extends from the bridge 36. The distal end 87 is located towardsthe first threaded 76 or second threaded wall 82. The ribs 89 taper fromthe distal end 87 to the proximal end, such that the width of the ribs89 is greater towards the distal end 87 than the proximal end. In theexemplary embodiment, the ribs 89 are positioned such that one of theribs 89 is located above the second rib 89 and that ribs 89 located onthe first front rib wall 79 are mirror images of the ribs 89 located onthe second front rib wall 85. The ribs 89 located on the first rear ribwall are mirror images of the ribs 89 located on the second rear ribwall. In other embodiments, there may only be one rib 89 extending fromeach rib wall or more than two ribs extending from each rib wall. Inother embodiments, the ribs 89 may have different dimensions from eachother on the same rib wall or between other rib walls. The ribs 89provide additional strength to the first threaded portion 32 and thesecond threaded portion 34.

Referring to FIG. 4, the transition portion 22 is generally circular inshape and includes a transition wall 88, a first indent 90 and a secondindent opposite from the first indent 90 (not visible in figure), adiameter D3 and a diameter D4. The first indent 90 and the second indentare mirror images that are located approximately 180° from each other.The first indent 90 has portions that are adjacent to the first threadedportion 32 and the second threaded portion 34. The front channel 72extends from the first threaded portion 32 and the second threadedportion 34 and terminates in the transition portion 22. The secondindent has portions that are adjacent to the first threaded portion 32and the second threaded portion 34. The rear channel 74 (not shown infigure) extends from the first threaded portion 32 and the secondthreaded portion 34 and terminates in the transition portion 22. Thetransition wall 88 is adjacent to the first threaded portion 32 and thesecond threaded portion 34. The transition wall 88 circumscribes the twosemi-circular top surfaces, the first top surface 80 and the second topsurface 86. The transition wall 88 tapers between the first indent 90and the second indent and the hollow cylindrical collar 20. The diameterD3 is the distance between the transition wall 88 adjacent to the hollowcylindrical collar 20. The diameter D4 is the distance between twopoints on the curved portions of the transition wall 88 adjacent to thefirst threaded portion 32 and the second threaded portion 34. In theexemplary embodiment, the diameter D4 is greater than D3. For example,the diameter D4 may be approximately 33 mm and the diameter D3 may beapproximately 30 mm. The diameter D4 is slightly less than the distancebetween the first threaded wall 76 and the second threaded wall 82 atpoints that are 180° from each other. In other embodiments, the diameterD4 may be substantially similar than or greater than the distancebetween the first threaded wall 76 and the second threaded wall 82 atpoints 180° from each other.

Referring to FIG. 4 and FIG. 5, the hollow cylindrical collar 20includes a collar side wall 92, a rim 94 that defines a substantiallycircular opening 96, a longitudinal axis 112 and a diameter D5. Anycontent passing between either the first chamber 14 or the secondchamber 18 and the opening 96 must pass through the hollow cylindricalcollar 20. The hollow cylindrical collar has a circular cross-sectionthat extends from the transition portion 22 to the rim 94. The collarside wall 92 extends between the rim 94 and the transition portion 22and is generally cylindrical in shape. The longitudinal axis 112 islocated through the center of the opening 96. The diameter D5 is thedistance of the opening 96. In the exemplary embodiment, the diameter D5may be less than the diameter D3. For example, the diameter D5 may beapproximately 30 mm and the diameter D3 may be 29 mm. In otherembodiments, the hollow cylindrical collar 20 may have an opening 96 andcross-section that are more square or oval in shape. In otherembodiments, the diameter D5 may be greater or substantially similar tothe diameter D3.

Referring to FIG. 6A and FIG. 6B, the transition portion 22 has aplurality of cross-sectional shapes. Referring to FIG. 6A, thetransition portion 22 has a circular cross-section that extends betweenthe first indent 90 and the second indent and the hollow cylindricalcollar 20 and in FIG. 6B, a cross-section that includes two opposed,hollow D-shaped surfaces that extends between the first indent 90 andthe second indent and the first threaded portion 32 and the secondthreaded portion 34. The transition portion 22 provides a content-tightjunction between the first threaded portion 32 of the first tapered neckportion 12 and the hollow cylindrical collar 20. The transition portion22 also provides a content-tight junction between the second threadedportion 34 of the second tapered neck portion 16 and the hollowcylindrical collar 20.

Referring to FIG. 7, the multiple-chamber container 10 after thetrimming process is shown. The transition portion 22 and the hollowcylindrical collar 20 are removed from the multiple-chamber container10, exposing the top surface, the first top surface 80 and the secondtop surface 86 that circumscribe two non-circular openings, a first neckopening 98 and a second neck opening 100. The first top surface 80 andthe second top surface 86 lay within a circular plane and are bothgenerally D-shaped. The first top surface 80 defines the first neckopening 98 on the first tapered neck portion 12. The second top surface86 defines the second neck opening 100 on the second tapered neckportion 16. The first neck opening 98 and the second neck opening 100are non-circular and are generally D-shaped. The first neck opening 98permits access into the interior of the first tapered neck portion 12and the first chamber 14. The second neck opening 100 permits accessinto the interior of the second tapered neck portion 16 and the secondchamber 18. The first neck opening 98 and the second neck opening 100may be covered with foil or plastic membrane. The first neck opening 98may be covered with a separate piece or the same piece of foil orplastic membrane as the second neck opening 100. The bridge 36 extendsbetween the first top surface 80 and the second top surface 86. Thefirst neck opening 98 and first top surface 80 are separated from thesecond neck opening 100 and the second top surface 86 by two gaps, onegap formed by the front channel 72 and the second gap formed by the rearchannel 74. The first top surface 80 and the second top surface 86 arecoplanar. The first top surface 80 and the first neck opening 98 is amirror image of the second top surface 86 and the second neck opening100. In other embodiments, the first top surface 80 and the first neckopening 98 may not be a mirror image of the second top surface 86 andthe second neck opening 100, but rather have different dimensions. Inother embodiments, the first neck opening 98 and the second neck opening100 may be more circular or oval in shape. In other embodiments, theneck openings may be of different shapes. For example, the first neckopening 98 may be generally D-shaped and the second neck opening 100 maybe generally oval shaped.

Referring to FIG. 7, a cap 102 is shown that includes a circular top104, a cylindrical skirt 106, an internal thread 108 and projections110. The cylindrical skirt 106 is formed with the circular top 104. Theinternal thread 108 of the cap 102 is configured to engage with thefirst external thread 78 and the second external thread 84. The cap 102is fully engaged with the multiple-chamber container 10, forming a sealwhen the internal thread 108 is engaged with the first external thread78 and the second external thread 84, forcing the circular top 104against the first top surface 80 and the second top surface 86. Thecontents of the multiple-chamber container 10 remain in the interior ofthe first chamber 14, the first tapered neck portion 12, the secondchamber 18 and second tapered neck portion 16 until the seal is tamperedwith or broken. The cap 102 fully engaged with the multiple-chambercontainer 10 prevents the contents of the container accidentally orunintentionally leaving the interior of either the first chamber 14, thefirst tapered neck portion 12, the second chamber 18 or second taperedneck portion 16. The cap 102 is configured to provide a user to removethe cap 102 by using a twisting motion to dispense the contents of themultiple-chamber container 10 and the cap 102 may be twisted back on tothe multiple-chamber container 10 to form the seal again. Theprojections 110 provide the user with a better grip of the cylindricalskirt 106 to assist with the twisting motion to remove and replace thecap 102. The cap 102 may also be configured to have the user push in ona designated area to release a tamper band and then apply the twistingmotion to remove the cap 102.

Referring to FIGS. 8A-8C and FIGS. 9A-9D, the trimming processes ofremoving the hollow cylindrical collar 20 and the transition portion 22are shown. As shown in FIGS. 8A-8C, one of the steps in a first methodto remove the transition portion 22 and the hollow cylindrical collar 20is to use a blade 114 to cut perpendicular to the longitudinal axis 112of the hollow cylindrical collar 20 through the transition portion 22.The blade 114 may remove the hollow cylindrical collar 20 and thetransition portion 22 in its entirety from the multiple-chambercontainer 10 by using a single cut or a series of cuts that pass throughthe entire diameter of the transition portion 22. As shown in FIGS.9A-9D, one of the steps in a second method to remove the transitionportion 22 and the hollow cylindrical collar 20 is to use a round blade116 that rotates around the multiple-chamber container 10, spiralinginwards towards the bridge 36, cutting perpendicularly to thelongitudinal axis 112 of the hollow cylindrical collar 20 through thetransition portion 22 until the hollow cylindrical collar 20 and thetransition portion 22 are completely separated from the multiple-chambercontainer 10. As shown in FIGS. 9A and 9B, one of the steps in a thirdmethod to remove the transition portion 22 and the hollow cylindricalcollar 20 is to use the round blade 116 that rotates around themultiple-chamber container 10, spiraling inwards towards the bridge 36,cutting a portion of the transition portion 22. As shown in FIG. 9C, theround blade 116 then moves in a first linear direction to make a cutfrom the transition portion 22 towards the bridge 36. After the roundblade 116 is completed with the first linear direction cut, the roundblade 116 moves 180° around the multiple-chamber container 10 from thefirst linear direction cut. The round blade 116 then makes a secondlinear direction cut from the transition portion 22 towards the bridge36. The round blade 116 continues with the second linear direction cutuntil the transition portion 22 and the hollow cylindrical collar 20 arecompletely separated from the multiple-chamber container 10 as shown inFIG. 9D.

Referring to FIGS. 8A-8C and FIGS. 9A-9D, the first top surface 80 thatis generally D-shaped, and the second top surface 86 that is generallyD-shaped, are exposed once the blade 114 or round blade 116 cuts throughthe entire transition portion 22, thereby completely separating thetransition portion 22 and the hollow cylindrical collar 20 from themultiple-chamber container 10. The first top surface 80 and the secondtop surface 86 are coplanar with each other and are coincident with oneof the cross-sections that fall within a plane and are formed byremoving the transition portion 22 and the hollow cylindrical collar 20from the first tapered neck portion 12 and the second tapered neckportion 16 at one of the cross-sections.

Referring to FIG. 10, a method for forming the multiple-chambercontainer 10 is provided, according to an exemplary embodiment. In oneembodiment, at step 200 a molten plastic extrusion is formed from 1 ormore different types of thermoplastic materials to produce 1 or morelayers of thermoplastic materials. The molten plastic extrusions thatare formed from using more than 1 type of thermoplastic material, theadjacent layers of thermoplastic materials are different from eachother. The walls forming the first chamber 14, the first tapered neckportion 12, the second chamber 18 and the second tapered neck portion16, the hollow cylindrical collar 20 and the transition portion 22 areformed from 1 or more layers of thermoplastic materials with at least 5additional layers of thermoplastic materials. At step 200 the moltenplastic extrusion may be formed to produce at least 6 layers of adjacentthermoplastic materials. Each of the adjacent layers of thermoplasticmaterial is different from each other. For example, high densitypolyethylene, low density polyethylene, polypropylene and polystyrenemay be the thermoplastic materials that form the adjacent layers in themultiple-chamber container 10. At step 202, a mold is closed around themolten plastic extrusion. The closed mold includes an interior mold wallthat defines an interior shape. The interior shape resembles the shapeof the multiple-chamber container 10. At step 204, a gas, such as air,is then forced into the molten plastic extrusion to expand the moltenplastic extrusion into contact with the interior mold wall to form acontainer having an outside shape that resembles the multiple-chambercontainer 10. At step 204, a pin (not shown) is used through the hollowcylindrical collar 20 during molding to assist the air in expanding themolten plastic extrusion. The outside shape of the multiple-chambercontainer 10 may be different from the interior shape of the mold by anamount defined by the effects of thermal deformation. Thermaldeformation may occur during the forming/molding process. The interiorshape of the mold causes the multiple-chamber container 10 to includethe first chamber 14, the second chamber 18, the first tapered neckportion 12, the second tapered neck portion 16, the hollow cylindricalcollar 20 and the transition portion 22. At step 206, the moldedmultiple-chamber container 10 that is formed from the molten plasticextrusion is cooled. At step 208, one of the trimming processesdiscussed above takes place. At step 208, the hollow cylindrical collar20 and the transition portion 22 is removed from the first tapered neckportion 12 and the second tapered neck portion 16 at the transitionportion 22 to produce the multiple-chamber container 10 that has thefirst top surface 80 and the second top surface 86 that circumscribesthe first neck opening 98 and the second neck opening 100 that areco-planar, non-circular openings.

Further modifications and alternative embodiments of various aspects ofthe invention will be apparent to those skilled in the art in view ofthis description. Accordingly, this description is to be construed asillustrative only. The construction and arrangements, shown in thevarious exemplary embodiments, are illustrative only. Although only afew embodiments have been described in detail in this disclosure, manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Someelements shown as integrally formed may be constructed of multiple partsor elements, the position of elements may be reversed or otherwisevaried, and the nature or number of discrete elements or positions maybe altered or varied. The order or sequence of any process, logicalalgorithm, or method steps may be varied or re-sequenced according toalternative embodiments. Other substitutions, modifications, changes andomissions may also be made in the design, operating conditions andarrangement of the various exemplary embodiments without departing fromthe scope of the present invention.

In various exemplary embodiments, the relative dimensions, includingangles, lengths and radii, as shown in the Figures are to scale. Actualmeasurements of the Figures will disclose relative dimensions, anglesand proportions of the various exemplary embodiments. Various exemplaryembodiments extend to various ranges around the absolute and relativedimensions, angles and proportions that may be determined from theFigures. Various exemplary embodiments include any combination of one ormore relative dimensions or angles that may be determined from theFigures. Further, actual dimensions not expressly set out in thisdescription can be determined by using the ratios of dimensions measuredin the Figures in combination with the express dimensions set out inthis description.

The present invention provides the ability to form multi-chamber,plastic containers with in excess of 4 to 5 layers using extrusion blowmolding. Containers discussed herein may include containers of anystyle, shape, size, etc. For example, the containers discussed hereinmay be shaped such that cross-sections taken perpendicular to thelongitudinal axis of the container are generally rectangular. However,in other embodiments the sidewall of the containers discussed herein maybe shaped in a variety of ways as may be desirable for differentapplications or aesthetic reasons. In various embodiments, the sidewallof container 10 may include one or more axially extending sidewallsections that are curved radially inwardly or outwardly such that thediameter of the container is different at different places along theaxial length of the container, and such curved sections may be smoothcontinuous curved sections. Container 10 may be of various sizes (e.g.,3 oz., 8 oz., 12 oz., 15 oz., 28 oz, etc.) as desired for a particularapplication.

What is claimed is:
 1. A method of forming a multiple-chamber containercomprising: extruding a molten thermoplastic extrusion; closing a moldaround the extrusion; the mold including an interior mold wall definingan interior shape; forcing a gas into the extrusion to expand theextrusion into contact with the interior mold wall to form a containerhaving an outside shape, the outside shape of the container differingfrom the interior shape of the mold by an amount defined by the effectsof thermal deformation occurring during the forming process, the moldincluding an interior shape causing the container to include: a firstchamber including a first bottom wall and a first side wall formed withthe first bottom wall and terminating at a first tapered neck portionwhich defines a first opening into the first chamber; a second chamberincluding a second bottom wall substantially coplanar with the firstbottom wall and a second side wall formed with the second bottom walland terminating at a second tapered neck portion which defines a secondopening into the second chamber, each neck portion including asemi-circular shaped surface having an external thread; a hollowcylindrical collar extending around a longitudinal axis and having acircular cross-section defining a substantially circular opening; and atransition portion which provides a content-tight junction between thefirst and second tapered neck portions and the hollow cylindrical collarsuch that any content passing between either chamber and the circularopening must pass through the hollow cylindrical collar; and moving ablade perpendicular to the longitudinal axis of the hollow cylindricalcollar through the transition portion to include: rotating the bladearound the container partially cutting the transition portion; movingthe blade in a first linear direction partially cutting the transitionportion; and moving the blade in a second linear direction differentfrom the first linear direction to completely cut the transitionportion; and removing the hollow cylindrical collar to produce acontainer having a coplanar top surface circumscribing two non-circularopenings.
 2. The method of claim 1, further comprising removing thetransition portion and the hollow cylindrical collar from the neckportions at a location which generates a top sealing surface for thecontainer including 2 non-circular openings, the top surface fallingwithin a plane.
 3. The method of claim 2, wherein the gas is air.
 4. Themethod of claim 3, further comprising moving a pin through the hollowcylindrical collar during molding to assist the air in expanding themolten thermoplastic extrusion.
 5. The method of claim 4, furthercomprising the step of cooling the mold.
 6. The method of claim 5,wherein the molten thermoplastic extrusion is formed to produce at least6 layers of adjacent thermoplastic materials wherein adjacent layers aredifferent from each other.